Foldable building units

ABSTRACT

Prefabricated foldable building units are described that have one or more of the following advantages. They are more easily prefabricated, more easily transported to building sites without requiring special permits, unloadable and unfoldable at the building sites without using cranes (they can be unloaded using ground-level lifting rigs and unfolded using, for example, a cable mechanism), allow precise and fast completion at the building site, and allow significant reduction in the scope of work to be completed on-site, where costs and scheduling are far less manageable. Further, methods for unloading and unfolding foldable building units are described that obviate the need for one or more cranes that can be expensive and project-complicating, thereby opening up a significant percentage of building sites for placement of prefabricated foldable building units.

RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.61/245,162, filed Sep. 23, 2009, U.S. Provisional Application No.61/371,524 filed Aug. 6, 2010, U.S. Provisional Application No.61/371,540, filed Aug. 6, 2010 and U.S. Provisional Application No.61/371,513, filed Aug. 6, 2010. The entire teachings of the aboveapplications are incorporated herein by reference.

BACKGROUND OF THE INVENTION

Architectural structures, particularly residential buildings, aretypically built on-site with each stage of the building processrequiring to transport necessary materials and specific skilled labor tothe site. The inherent cost inefficiency of this approach is well knownin the art.

Thus, alternative approaches have been described aimed at providingeconomically priced housing. Some of these alternatives includedprefabricating various parts of a building at a central facility,transporting the parts to a building site and then completing theassembly on-site. Other alternatives included prefabricating foldablebuilding units at a central facility, transporting the foldable buildingunits to a building site, unloading and unfolding the foldable buildingunits on-site using cranes, and then completing the assembly on-site.However, it has been described that for a number of reasons, theinstallation cost of prefabricated non-foldable building units wassubstantial and, when added to the cost of manufacture and delivery,caused the total cost of these prefabricated non-foldable building unitsto rise to levels detrimental for competition with conventionalconstruction. Previously described foldable building units have one ormore of the following disadvantages. They require substantial work atthe building site, substantial time for finishing at the building site,they are difficult to prefabricate, they do not allow precise unfoldingand finishing at the building site, and they require cranes forunloading and unfolding at the building site. Cranes can be veryexpensive to employ, difficult to schedule, and are not even suitablefor a significant percentage of building sites, thus, excluding thesebuilding sites for a substantial number of prefabricated foldablebuilding units and often requiring home owners or developers ofrespective building sites to use conventional construction.

There is, therefore, a need for foldable building units that cost less,allow improved precision at the building site, are easier toprefabricate, transport, and unfold and finish quickly at the buildingsite, and can be placed at building sites that were previously notsuitable for placement of prefabricated foldable building units.

SUMMARY OF THE INVENTION

One embodiment of the present invention is a foldable building unit. Thefoldable building unit includes a structural frame that at least in partis made of frame elements that are foldably connected with metal hinges.It further includes interior finish materials with indirect connectionto the frame elements to reduce direct contact of the interior finishmaterials with the frame elements. The frame elements are at least inpart made of metal and the metal hinges are attached to a metal part ofthe frame elements.

Another embodiment of the present invention is a foldable building unitthat includes a structural frame that at least in part is made of frameelements that are foldably connected with offset hinges. The offsethinges are attached to metal parts of the frame elements and the offsethinges are adapted and positioned on the frame elements such that whenfolded, interior finish materials connected to the frame elements areoffset from each other.

Another embodiment of the present invention is a foldable building unitthat includes a structural frame that at least in part is made of frameelements that are foldably connected with metal hinges, wherein theframe elements are at least in part made of metal, the metal hinges areattached to a metal part of the frame elements, and the metal hinges areadapted and positioned to remain within the building unit in unfoldedconfiguration and finished condition.

Another embodiment of the present invention is a foldable building thatincludes foldably connected finished wall panels, foldably connectedfinished floor panels, and foldably connected finished ceiling and/orroof panels. The foldable building in unfolded configuration issubstantially in finished condition.

Another embodiment of the present invention is a foldable buildinghaving a structural frame adapted to be connected to ground-levellifting rigs to lift or lower the foldable building.

Another embodiment of the present invention is a method for unloading afoldable building unit from a transport vehicle. The method includes (a)placing ground-level lifting rigs next to the transport vehicle inpositions adapted to allow attaching lifting members of the ground-levellifting rigs to the foldable building unit and to allow lifting of thefoldable building unit; (b) attaching lifting members of the liftingrigs to the foldable building unit; (c) operating the lifting rigs tolift the foldable housing module off the transport vehicle; and (d)driving the transport vehicle to a location to remove the loading areaof the transport vehicle from underneath the foldable housing module.

Another embodiment of the present invention is a method for unfolding afolded building unit. The method includes unfolding folded frameelements that are part of a structural frame of the folded building unitfrom a folded configuration to an unfolded configuration using one ormore of a cable mechanism, hydraulic mechanism or air actuationmechanism.

Another embodiment of the present invention is a foldable buildingcomprising a core structure made of first frame elements in fixedconnection, and second frame elements hingedly connected, directly orindirectly, to the core structure. The second frame elements are made ofmetal members, and the core structure and the second frame elements arepart of the structural frame of the foldable building.

Another embodiment of the present invention is a foldable building unitcomprising (a) a structural frame that at least in part is made of frameelements that are foldably connected with offset hinges, and (b)interior finish materials with indirect connection to the frame elementsto reduce contact of the interior finish materials with the frameelements, wherein the frame elements are at least in part made of metal,the offset hinges are attached to a metal part of the frame elements,and the offset hinges are adapted and positioned on the frame elementssuch that when folded, interior finish materials connected to the frameelements are offset from each other.

Another embodiment of the present invention is a foldable building unitcomprising (a) a structural frame that at least in part is made of frameelements that are foldably connected with metal hinges, and (b) interiorfinish materials with indirect connection to the frame elements toreduce contact of the interior finish materials with the frame elements,wherein the frame elements are at least in part made of metal, the metalhinges are attached to a metal part of the frame elements, and the metalhinges are adapted and positioned to remain within the building unit inunfolded configuration and finished condition.

Another embodiment of the present invention is a foldable building unitcomprising (a) a structural frame that at least in part is made of frameelements that are foldably connected with offset hinges, and (b)interior finish materials with indirect connection to the frame elementsto reduce contact of the interior finish materials with the frameelements, wherein the frame elements are at least in part made of metal,the offset hinges are attached to a metal part of the frame elements,the offset hinges are adapted and positioned on the frame elements suchthat when folded, interior finish materials connected to the frameelements are offset from each other, and the offset hinges are metalhinges adapted and positioned to remain within the building unit inunfolded configuration and finished condition.

Another embodiment of the present invention a foldable buildingcomprising (a) a core structure made of first frame elements in fixedconnection, (b) second frame elements hingedly connected, directly orindirectly, to the core structure, wherein the second frame elements aremade of metal members, and the core structure and the second frameelements are part of the structural frame of the foldable building; and(c) interior finish materials with indirect connection to the secondframe elements to reduce direct contact of the interior finish materialswith the frame elements, wherein one or more of the second frameelements are hingedly connected with offset hinges attached to the frameelements, and the offset hinges are adapted and positioned on the frameelements such that when folded, interior finish materials connected tothe frame elements are offset from each other.

Another embodiment of the present invention is a foldable buildingcomprising (a) a core structure made of first frame elements in fixedconnection, (b) second frame elements hingedly connected, directly orindirectly, to the core structure, wherein the second frame elements aremade of metal members, and the core structure and the second frameelements are part of the structural frame of the foldable building; and(c) interior finish materials with indirect connection to the secondframe elements to reduce direct contact of the interior finish materialswith the frame elements, wherein one or more of the second frameelements are hingedly connected with metal hinges attached to the frameelements, and the metal hinges are adapted and positioned to remainwithin the building unit in unfolded configuration and finishedcondition.

Another embodiment of the present invention is a foldable buildingcomprising (a) a core structure made of first frame elements in fixedconnection, (b) second frame elements hingedly connected, directly orindirectly, to the core structure, wherein the second frame elements aremade of metal members, and the core structure and the second frameelements are part of the structural frame of the foldable building; and(c) interior finish materials with indirect connection to the secondframe elements to reduce direct contact of the interior finish materialswith the frame elements, wherein one or more of the second frameelements are hingedly connected with offset hinges attached to the frameelements, and the offset hinges are adapted and positioned on the frameelements such that when folded, interior finish materials connected tothe frame elements are offset from each other, and the offset hinges areadapted and positioned to remain within the building unit in unfoldedconfiguration and finished condition.

Another embodiment of the present invention comprises a combination oftwo or more, including all, of the above embodiments.

The foldable building units of the present invention have one or more ofthe following advantages. They are more easily prefabricated, allow moreflexibility in building shapes including higher ceilings and largerspaces, reduce or eliminate material damage due to, for example,shipment, structural deflection, thermal flexure and contraction, andstructural aging, more easily transportable to building sites withoutrequiring special permits, unloadable and unfoldable at the buildingsites often without using cranes (they can be unloaded usingground-level lifting rigs and unfolded using, for example, a cablemechanism) and allow significant reduction and increased speed of workto be completed on-site, where typically costs and scheduling are farless manageable.

Additionally, as mentioned above, the methods for unloading andunfolding foldable building units of the present invention can obviatethe need for cranes that can be expensive and project-complicating,thereby opening up a significant percentage of building sites forplacement of prefabricated foldable building units.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing will be apparent from the following more particulardescription of example embodiments of the invention, as illustrated inthe accompanying drawings in which like reference characters refer tothe same parts throughout the different views. The drawings are notnecessarily to scale, emphasis instead being placed upon illustratingembodiments of the present invention.

FIG. 1 is a perspective view of a foldable building in unfoldedconfiguration without interior and exterior finishing.

FIG. 2 is a perspective view of a foldable building in unfoldedconfiguration without interior and exterior finishing.

FIG. 3 is a perspective view of the foldable structural frame of thefoldable building shown in FIG. 1 in unfolded configuration, and furtherprovides detail views of some of the structural features of thestructural frame.

FIG. 4 is a perspective view of an unfolding sequence of the foldablestructural frame of the foldable building of FIG. 1 from the foldedconfiguration on the left-hand side to the unfolded configuration on theright-hand side.

FIG. 5 is a perspective view of a frame element made of four hollowstructural steel sections and intermediate elements attached to theframe element.

FIG. 6 is a cross-sectional view illustrating a powder actuated fastenerconnection of a lumber sill to the hollow structural steel section ofFIG. 5.

FIG. 7 is a perspective view of a finished wall panel or section.

FIG. 8 is a cross-sectional view illustrating indirect connection ofinterior finish materials with a respective frame element.

FIG. 9 provides a perspective view of four folding configurations of athree-axis step-out hinge.

FIG. 10 provides a front (at top of figure) and top view (at bottom offigure) of two frame elements that are foldably connected with athree-axis step-out hinge.

FIG. 11 is a top view of the hinge area of the two foldably connectedframe elements shown in FIG. 10 for four folding configurations.

FIG. 12 is a perspective view of a fixed-axis offset hinge.

FIG. 13 is a cross-sectional view of two foldably connected hollowstructural steel sections in which the seam or fold between the hollowstructural steel sections as well as the hinge(s) are covered with aflexible polymer gasket.

FIG. 14 is a cross-sectional view of part of a finished wall panel orsection.

FIG. 15 is a perspective view of four ground-level lifting rigs holdingthe folded structural frame of a foldable building.

FIG. 16 is a perspective view illustrating steps of the uploading (fromleft to right) or unloading (from right to left) of a foldable buildingunit on a transport vehicle.

FIG. 17 is a perspective view of an unfolding sequence of the foldablestructural frame of the foldable building of FIG. 2 from the foldedconfiguration on the left-hand side to an unfolded configuration on theright-hand side.

FIG. 18 is a cross-sectional view of a folding wall corner in unfoldedconfiguration and substantially finished condition.

FIG. 19 is a cross-sectional view of the folding wall corner of FIG. 18in finished condition.

FIG. 20 illustrates the use of a cable mechanism in unfolding andfolding of a foldable floor section of a foldable building unit.

FIG. 21 is a cross-sectional view of a hinged wall detail in unfoldedconfiguration and substantially finished condition.

FIG. 22 is a cross-sectional view of the hinged wall detail of FIG. 21in finished condition.

FIG. 23 is a perspective view of an unfolding sequence of one embodimentof a clerestory-shaped single-story foldable building of the presentinvention

FIG. 24 is a cross-sectional view of a fixed-axis offset hinge in anunfolded configuration with each hinge leave attached to a structuralmember.

DETAILED DESCRIPTION OF THE INVENTION

A description of example embodiments of the invention follows.

Although the teachings of the present invention are applicable to a widevariety of structures of different weight, size, shape and materials fora variety of diverse uses, for purposes of the following description,the present invention will be described in the context of prefabricatedfoldable building units.

The foldable buildings (and, more generally, foldable building units) ofthe present invention can be prefabricated such that the foldablebuildings, after unfolding on the building site, are substantially infinished condition. That is, they do not require or significantly reducethe addition of further building sections such as wall panels, floor androof sections, or the addition of interior and exterior finish materialswith the exception of minor, non-structural finishing in areas requiredfor folding movement. However, the prefabrication process can be reducedsubstantially, even to the extent that merely a foldable structuralframe of the present invention is prefabricated and unfolded at thebuilding site.

Further, all necessary mechanical and electrical systems for theresidential or commercial foldable building, for example, all therequired appliances and plumbing fixtures, can be installed in a corestructure (i.e., a part of the structural frame of the foldable buildingthat is made of frame elements that are not unfolded at the buildingsite, typically, frame elements that share at least one fixed seamconnection with another frame element) of the foldable building at thetime of its prefabrication. At this point, the foldable building hasbeen brought into finished condition and only requires connection to thelocal utilities, e.g. electricity and sewerage, and seam connections forit to be completed.

FIG. 1 is a perspective view of a foldable building 100 in unfoldedconfiguration without interior and exterior finishing. The foldablebuilding contains a structural frame that includes interconnected frameelements 110 made of hollow structural steel sections and woodenintermediate elements 120 attached thereto. Selected frame elements arefoldably connected with hinges 130 that can be of various designsdescribed herein. For ease of illustration, interior and exteriorfinishing materials are not shown. Such materials are preferablyattached (e.g., glued, nailed, screwed, welded and/or bolted, orotherwise fastened) to the intermediate elements 120.

Use of appropriately dimensioned metal sections, more typically, hollowstructural steel sections as shown in FIG. 1, as part of a foldablestructural frame of a foldable building unit, and, particularly,foldably connected frame elements made of hollow structural steelsections, have been found to be advantageous for a number of reasonsincluding the following: Fewer and/or smaller hinges (typically, metalhinges) can be used to foldably connect frame elements, reducing laborand material cost in the prefabrication process, reducing the cost ofon-site finishing, and increasing the precision of the folding andunfolding of foldably connected frame elements thereby further reducingthe labor and material cost of on-site finishing by enablingprefabrication of interior and exterior materials that fit into theunfinished areas (e.g., seams of foldably connected frame elements)after unfolding (see, e.g., FIGS. 18 and 19 with regard to finishingmaterial that is desired and can be prefabricated to complete a typicalfolding wall corner with minimal on-site labor). Large frame geometriesas part of the structural frame, for example, rectangular frame elementsspanning the entire side of a foldable building can be employed (see,e.g., the wall frame element 450 in FIG. 4), reducing prefabricationcost and/or simplifying the unfolding.

Further, foldable structural frames substantially made of metal frameelements (e.g., made from hot-formed steel, for example, from hollowstructural steel sections) can be prefabricated to superior tolerancessuch that a respective foldable building unit in substantially finishedcondition upon unfolding exhibits reduced or no gaps in the seam areasbetween foldably connected frame elements thereby reducing the workassociated with on-site finishing of these seam areas.

FIG. 2 is a perspective view of a further foldable building 200 inunfolded configuration without interior and exterior finishing. Thefoldable building contains a structural frame that includesinterconnected frame elements 110 made of hollow structural steelsections and wooden intermediate elements 120 for attachment of finishmaterials (not shown). Selected frame elements are foldably connectedwith hinges 130. The foldable building includes frame elements that areunfolded during unfolding and others that remain fixed. The roof of thefoldable building includes a fixed roof section 210 and a foldable roofsection 215 which is foldably connected with hinges 130 to the fixedroof section 210. The floor of the foldable building includes a fixedfloor section 220 foldably connected to a foldable floor section 225.Further, the fixed roof section 210 and fixed floor section 220 are infixed connection with fixed wall sections 230, 232 and 234. Fixed wallsection 232 is foldably connected with the foldable wall section 240which itself is further foldably connected to foldable wall section 242.Fixed wall section 234 is foldably connected with the foldable wallsection 244 which itself is further foldably connected to foldable wallsection 246. Foldably connected sections are connected with hinges (notall hinges shown) attached to the frame elements of the respectivesections.

Foldable building units, for example, the foldable buildings shown inFIGS. 1 and 2, can further include a number of prefabricated interiorwalls (not shown) that can be fixed, foldably connected, or panelizedand form one or more rooms in the unfolded building.

The foldable buildings of the present invention can be several storieshigh. With the use of a crane, multi-story structures can be builton-site by stacking separate foldable building units with a crane. Inthis arrangement, ceiling frame elements of the lower unfolded foldablebuilding unit lie directly below floor frame elements of the upperfoldable building unit. During prefabrication, appropriate openings canbe included in the ceiling of the lower foldable building unit and inthe floor of the upper foldable structure to accommodate a staircase,which can be installed in the lower foldable building unit duringprefabrication.

FIG. 3 is a perspective view of the foldable structural frame of thefoldable building shown in FIG. 1 in unfolded configuration, includingdetail views of some of the structural features of the structural frame.

FIG. 4 is a perspective view of an unfolding sequence of the foldablestructural frame of the foldable building of FIG. 1 from the foldedconfiguration 400 on the left-hand side to the unfolded configuration300 on the right-hand side. The unfolding sequence is shown for thefoldable structural frame; however, the same unfolding sequence can beused for a respective substantially finished foldable building. The roofframe elements 410 and 420, and the clerestory truss frame element 430are lifted (e.g., with a cable mechanism) to provide unfolding space forthe floor frame element 440 which is foldably connected to the wallframe element 450. Floor frame element 440 is folded downward to theground and wall frame element 450 upward to establish a wall (e.g.,front wall) of the foldable building, Then, the roof frame elements 410and 420 can be lowered onto and connected to the wall frame element 450,followed by the unfolding of the wall frame elements 460, 470 and 480(note that wall frame element 480 is foldably connected and part of thestructural frame 400 but only shown in for the foldable building inunfolded configuration 300). It is to be understood, that the aboveunfolding sequence is not the only possible sequence for unfolding thefoldable building 400. For example, the wall frame elements 460 and 470could be unfolded, at least partly, prior to unfolding or completing theunfolding of roof frame elements 410 and 420. The core structure of thestructural frame is provided by the frame elements that are not movedduring unfolding to the unfolded configuration 300.

Foldable building units of the present invention can unfold from oneside of a core structure of the structural frame of the foldablebuilding unit as shown, for example, in FIG. 4, but can also be designedto unfold from a plurality of sides. For example, a foldable building ofthe present invention can be adapted to unfold in two oppositedirections.

FIG. 5 is a perspective view of an unfinished wall section or panel 500that includes a frame element made of four structural steel sections 510and intermediate elements attached to the frame element. Theintermediate elements are a lumber sill 520 (i.e., a wooden bottom plateelement) and a lumber header 530 (i.e., a wooden top plate element),both fastened to the frame elements with powder actuated fasteners orother suitable fasteners 540 (fasteners connecting the lumber header 530to the frame element are not visible in this perspective view). Lumberstuds 550 (i.e., stud elements) are fastened between the lumber header530 and the lumber sill 520. Interior finish materials can be attached(e.g. nailed, screwed, fastened and/or glued) to the intermediateelements (here, lumber) to connect indirectly to the frame element.

Steel frame elements can be combined with wooden intermediate elementsas shown in FIG. 5 to form lightweight steel and wood hybrid structuresin which the frame elements provide structural stability and the woodenintermediate elements provide substantial lateral structural resistanceand are used to attach interior and exterior finishing material usingstandard construction approaches, reducing labor training and associatedcosts. Use of these strong and lightweight structures (and, inparticular, the use of the foldable structural frames of the presentinvention) substantially reduces the amount of required buildingmaterial, and also allows reduced weight of the frame elements and,thus, reduced weight of the foldable building unit, which in turnfacilitates the transport of larger folded building units for a givenmaximal allowed weight according to given road regulations. Further, areduced weight of foldably connected frame elements can facilitate theunfolding of these frame elements without the use of a crane.

FIG. 6 is a cross-sectional view illustrating a powder actuated fasteneror other suitable fastener connection of the lumber sill 520 to thestructural steel section 510 of FIG. 5. The lumber sill 520 ispositioned and dimensioned to provide a wood offset 610 from the steelof the hollow structural steel section 510. The wood offset 610 canreduce or prevent contact of interior finish material (not shown; e.g.drywall attached to the lumber sill 520) with the steel. It can alsoreduce heat transfer and/or reduce or prevent contact of potentialcondensate formed on the steel with interior finish material.

It has been found that the use of powder actuated fasteners allowsestablishment of a strong connection between wooden intermediateelements and steel frame elements (in particular, made of hollowstructural steel sections) quickly, reducing the prefabrication cost andproviding significant connection strength.

FIG. 7 is a perspective view of a finished wall panel or section 700,which can be obtained by attaching interior finish material, such asgypsum wall board 710 and a baseboard 720, to an unfinished wall panel.The finished wall panel 700 includes interior finish material, such asgypsum wall board 710 and a baseboard 720, with indirect connection tothe respective frame element. The indirect connection is furtherillustrated in FIG. 8.

FIG. 8 is a cross-sectional view illustrating indirect connection ofinterior finish materials with a respective frame element. Interiorfinish material, such as a gypsum wall board 710, is attached to abottom plate (here, a wood sill plate 520) which in turn is fastenedusing a powder actuated fastener or other suitable fastener 540 to thehollow structural steel section 510. A baseboard 720 is attached to thegypsum wall board 710 and optionally a plywood backer board 810 fillsthe wood offset gap.

The indirect connection shown in FIG. 8 is one of a number of possibleconnections that allow reduction of structural stress transfer from thestructural frame to interior finishing materials, reduce heat loss, andimprove moisture control. A further indirect connection is shown inFIGS. 18 and 19.

Indirect connections of interior and/or exterior finishing materials tometal frame elements (particularly, frame elements made of structuralsteel sections) are one aspect of a “multi-tolerance” building approachthat disaggregates and cushions brittle or otherwise fragile finishmaterials from the vibrational, kinetic and settling forces applied tothe structural frame during shipping, setting, unfolding and settling ofthe prefabricated foldable building units. A second aspect of amulti-tolerance building approach is provided by the offset hinges ofthe present invention which are specifically engineered to safely nesthingedly (i.e., foldably connected with one or more hinges) connectedframe elements at a designed distance away from its neighboring frameelement, allowing, for example, for thicker wall depths and thus theprefabricated inclusion of finish materials. This is associated with asignificant reduction in the scope of work to be completed on-site,where costs and scheduling are far less manageable. Thus, foldablebuilding units of the present invention can include final interiorfinishing, such as trim, gypsum board, paint or wallpaper.

FIG. 9 is a perspective view of four folding configurations of athree-axis step-out hinge 900 (e.g., a type of offset hinge). Hingeleaves 910 extend into hinge knuckles 920 surrounding hinge pins 930.Center hinge leaves 940 extend in two directions into hinge knuckles 920surrounding hinge pins 930. The folding configurations can be part of afolding and/or unfolding sequence.

The three-axis step-out hinges provide folding flexibility and canincrease the packing/folding degree of a foldable building unit.

FIG. 10 provides a front view (at top of figure) and top view (at bottomof figure) of two frame elements 110 that are foldably connected with athree-axis step-out hinge 900.

FIG. 11 is a top view of the hinge area of the two foldably connectedframe elements 110 shown in FIG. 10, providing four foldingconfigurations that can be part of an unfolding sequence from anunfolded configuration (for example, the folding configuration shown onthe left-hand side) to the folded configuration shown on the right-handside. One of the frame elements 110 is connected to one of the hingeleaves 910 of the three-axis step-out hinge through a spacer element1110 dimensioned and positioned such that a planar surface is jointlyformed by the two foldably connected frame elements in the unfoldedconfiguration shown on the left-hand side of the figure. As can be seenfor the folded configuration, a three-axis step-out hinge can provide anoffset 1120. Thus, interior finish materials (not shown) attached to theframe elements can be offset from each other.

FIG. 12 is a perspective view of a fixed-axis offset hinge. Hinge leaves910 with extended hinge knuckles 1210 surrounding a hinge pin 930 can berotated around the axis provided by the hinge pin 930. In completelyfolded configuration (not shown) the offset hinge provides an offsetwhich increases with the length of the extension 1220 of the extendedhinge knuckles 1210. Thus, interior finish materials (not shown)attached to the frame elements can be offset from each other.

FIG. 13 is a cross-sectional view of two foldably connected hollowstructural steel sections 510 in which the seam or fold between thehollow structural steel sections 510 as well as the hinge(s) 1310 arecovered with a flexible polymer gasket 1320 which is attached (forexample, glued) to the hollow structural steel sections.

FIG. 14 is a cross-sectional view of part of a finished wall panel orsection illustrating indirect connection of the of interior and exteriorfinish materials to a structural steel section of a frame element. Twointermediate elements, a wood face plate 1410 and a wood plate 1420(e.g., lumber sill) are attached to a rectangular structural steelsection 1430. A wood stud 1440 is further attached to the wood plate1420. Interior finish material 1460 (for example, gypsum board) isattached to the wood plate 1420. Exterior finish material 1450 (forexample, plywood or OSB sheating) is attached to the wood face plate1410, the wood plate 1420, and/or the wood stud 1440.

FIG. 15 is a perspective view of four ground-level lifting rigs 1510holding a folded steel assembly 1520 of a foldable building. Only thesteel assembly is shown; however, foldable building units in variousfinished conditions, can be held, lifted and lowered using ground-levellifting rigs such as the ones that are shown. Each lifting rig 1510includes a hoist 1530 (e.g., manual or electric) and a lifting member1540 (e.g., chain with hook for connection to a solid stock steel rig).Connection members 1550 (e.g., a solid stock steel rig) are connected tothe lifting members 1540 of the ground-level lifting rigs 1510.Connection members can be part of the folded steel assembly andextendable into an extended position as shown, or they can be separateparts that are inserted into the folded steel assembly (e.g., intohollow structural steel sections of a floor frame element).

FIG. 16 is a perspective view illustrating the steps of uploading (fromleft to right) or unloading (from right to left) of a foldable buildingunit (here, the folded foldable building unit is illustrated in terms ofits folded steel assembly 1520) on a transport vehicle 1610. Foruploading, the ground level lifting rigs are placed next to the foldablebuilding unit (which is folded sufficiently to comply with transportregulations). The folded steel assembly 1520 and lifting members of theground-level lifting rigs are attached to the folded building unit. Thenthe lifting rigs are operated to lift the folded building unit up to aheight sufficient to allow the transport vehicle 1610 to drive itsloading area 1620 under the folded steel assembly. On the left, fourground-level lifting rigs 1510 are holding the folded steel assembly1520 at a height sufficient to allow the transport vehicle 1610 to driveits loading area 1620 under the folded steel assembly 1520. Thetransport vehicle 1610 moves its loading area 1620 under the foldedsteel assembly as shown in the middle and on the right of the figure.After the loading area 1620 has been placed appropriately under thefolded building unit as shown at the right, the lifting rigs can beoperated to lower it onto the loading area. The ground-level liftingrigs can then be disconnected, and, if desired, also transported to abuilding site for use in unloading of the foldable building unit.

FIG. 17 is a perspective view of an unfolding sequence of the foldablestructural frame of the foldable building of FIG. 2 from the foldedconfiguration 1700 on the left-hand side to an unfolded configuration1710 on the right-hand side. The unfolding sequence is shown for thefoldable structural frame; however, the same unfolding sequence can beused for the respective substantially finished foldable building. Firsta floor 1720 and/or roof panel 1730 is unfolded, then two separate pairsof hingedly connected wall panels 1740 and 1750 are unfolded to completethe building envelope.

FIG. 18 is a cross-sectional view of a folding wall corner in unfoldedconfiguration and substantially finished condition. A hinge 1810 isattached to members 1820 (typically, hollow structural steel sections)of two foldably connected frame elements. Intermediate elements 1830(e.g., lumber) are attached to the members 1820. Interior finishmaterials, such as drywalls 1840, are attached to intermediate elements1830. Exterior finish materials such as sheathing 1850 (e.g., Advantech®sheathing), housewrap 1860, siding 1870 (e.g. wood or corrugated steelsiding), and plywood 1880 are directly or indirectly attached to theintermediate elements 1830 in a manner that leaves unfinished areas 1890dimensioned to accommodate folding of the frame elements.

FIG. 19 is a cross-sectional view of the folding wall corner of FIG. 18in finished condition. Additional interior finish material such asdrywall 1910 is attached (e.g., drywall glued and/or screwed) to theintermediate element with tape 1920 at the seams. Further, foam 1930 andexterior finish material such as wood trim 1940 is added to finish theexterior unfinished area.

FIG. 20 illustrates the use of a cable mechanism in unfolding andfolding of a foldable floor section 2000 of a foldable building unit.For ease of illustration, merely part of a structural frame of afoldable building unit in cross-sectional view is provided. A cable 2010of an electric winch 2020 (attached, for example, to a fixed part of thestructural frame) is guided through appropriately selected frameelements to a position that is suitable for folding (here lifting) orunfolding (here lowering) of the foldable floor section 2000. If thecable is attached to the clerestory truss, the cable mechanism can beused to raise or lower the clerestory truss.

FIG. 21 is a cross-sectional view of a hinged wall detail 2100 inunfolded configuration and substantially finished condition. A hinge2110 foldably connects a first structural member 2120 (typically, astructural steel section) of a first substantially finished panel (onlypart of which is shown in the cross-sectional view) with a secondstructural member 2130 (typically, a structural steel section) of asecond substantially finished panel (only part of which is shown in thecross-sectional view). Intermediate elements 2140 and 2150 (e.g., herelumber) are attached to the members 2120 and 2130, respectively.Interior finish materials, such as drywall 2160, are attached to theintermediate elements 2140 and 2150. Exterior finish materials such assheathing 2170 (e.g., Advantech® sheathing), siding 2180 (e.g. wood orcorrugated steel siding), and plywood 2190 are directly or indirectlyattached to the intermediate elements 2140 and 2150 in a manner thatleaves unfinished areas 2195 dimensioned to accommodate folding of theframe elements.

A foldable connection between two substantially finished wall panels caninclude one or more, typically, at least two hinges, that can beconfigured and positioned as shown, for example, in FIG. 21.

FIG. 22 is a cross-sectional view of the hinged wall detail of FIG. 21in finished condition 2200. Additional interior finish material such asfoil backed drywall 2210 is attached (e.g., glued and/or screwed) to theintermediate element with tape 2220 at the seams. Further, foam 2230 andexterior finish material such as wood (e.g. cedar) trim 2240 is added tofinish the exterior unfinished area.

The hinged wall detail of FIGS. 21 and 22 separates the structuralmembers from direct contact with the finish-grade materials which aremore brittle and would tend to degrade if forces from the structuralmembers were substantially transferred to them. Moreover, the hingedwall detail does not provide a direct metal pathway between the exteriorand interior of the structure in order to prevent undesirable transferof heat between the interior and exterior of the structure.

FIG. 23 is a perspective view of an unfolding sequence for oneembodiment of a clerestory-shaped single-story foldable building of thepresent invention from the folded configuration 2300 to an unfoldedconfiguration 2310. The folded building is very compact and properlydimensioned to allow for efficient transport to the building site. Theunfolding sequence can be used with one or more, and, more typically,all of the panels (fixed and foldable connected ones) in substantiallyfinished condition; even windows 2320 and doors 2330 can be part of thefolded building. Firstly, a floor panel 2340 hingedly connected to acore structure 2350 of the foldable building is unfolded. The floorpanel 2340 is further hingedly connected to a wall panel 2360, whichtypically is unfolded after the floor panel 2340 has been unfolded.Further wall panels 2370 and 2380 hingedly connected to the corestructure are unfolded and fastened to the unfolded wall panel 2360.Then the roof panel 2390 is unfolded and fastened to one or more of theunfolded wall panels.

FIG. 24 is a cross-sectional view of a fixed-axis offset hinge 2410 witheach hinge leave 2420 attached to a structural member (typically,structural steel member) shown in an unfolded configuration. Typically,fixed-axis offset hinges such as the one shown in the drawing areattached to the structural members so that a tolerance 2420 (e.g., ⅛″)is provided. In completely folded configuration (not shown) the offsethinge provides an offset, which allows sufficient clearance for finishand other materials. Further, the interior finish materials (not shown)attached to the frame elements can be sufficiently offset from eachother to avoid direct and potentially damaging contact, for example,during transport.

The foldable building units of the present invention can be adapted toaccommodate unfolding using a robust, cost-effective cable mechanismenabling the smooth and facile unfolding of prefabricated homes,on-site, without the need for a crane or cranes which can be expensiveand project complicating.

Specifically, foldable structural frames of the present invention caninclude frame elements made at least in part of materials with pointload strengths adapted for point loading arising from pulling therespective frame elements with a device such as a cable hoist.

The use of ground-level rigs of the present invention can have severaladvantages compared to the use of cranes for unloading foldable buildingunits including the following. Ground-level lifting rigs can be used forunloading foldable building units on building sites that are not suitedfor the use of cranes or even accessible by cranes. Further,ground-level rigs can be transported along with the folded building uniton the transport vehicle, thus, allowing unloading at any desired timewithout advance scheduling (as is typically required if cranes areused).

A “foldable building unit” as used to herein, is a part of a building oran entire building, wherein the part or entire building are foldable,that is, can be folded from an unfolded configuration to a foldedconfiguration and vice versa. For example, a foldable building unit canbe one or more foldable rooms of a building, a foldable story of abuilding, or an entire foldable building. Preferably, the foldablebuilding unit is an entire foldable building. A foldable part of abuilding or an entire foldable building can be several stories high inunfolded configuration, typically, however, more typically, one or twostories high. A foldable building unit in “unfolded configuration” is afoldable building unit in which the foldably connected frame elementshave been unfolded into positions that can be maintained in the finishedcondition of the foldable building unit. A foldable building unit in“folded configuration” is a foldable building unit in which foldablyconnected frame elements are folded into positions suitable foruploading, transport, and/or unloading of the building unit. Thefoldable building or foldable building unit can be a commercial orresidential building.

The present invention also encompasses buildings that are more than twostories high. Such buildings can be built from one unfolding buildingunit or from a plurality of foldable building units, for example, eachfoldable building unit being typically one or two stories of the finalmulti-story building. Typically, in many locations, use of a crane isnot desirable due to associated cost and possible crane schedulingdifficulties. However, if buildings with more than two stories are to beset up on the building site, more typically, a crane can be employed.

Foldable buildings of the present invention can have one or more rooms.

A “structural frame” as used herein, refers to the totality of membersof a foldable building unit that are primarily responsible for providingstructural stability of the foldable building unit in folded, partiallyunfolded and unfolded configuration, and which transmit loads (e.g.,static, dynamic, and/or vibrational loads) to the ground. A structuralframe of a foldable building unit can be made at least in part of frameelements that are foldably connected. Other parts of the structuralframe can be connected in fixed relative positions. Typically, astructural frame can comprise both, foldably connected frame elementsand frame elements in fixed relative positions. However, the structuralframe can also consist entirely of foldably connected frame elements.Structural frames can include members that are made of a plurality ofmaterials in various forms and dimensions. Suitable materials that canbe used include but are not limited to wood, metal (e.g., aluminum orsteel) and polymers. Suitable forms include but are not limited toI-beams, wide-flange beams, angles, hollow structural sections andchannel sections. The selection of a material, form and dimension for agiven structural part or member of a structural frame is interdependentand depends on factors such as the position of the structural part ormember in the structural frame, and whether the member is part of aframe element that is foldably connected.

A “frame element” as used herein, refers, to an element of a structuralframe of a foldable building unit that includes a plurality of membersthat form a closed or open frame. Typically, the members form a closedframe. However, the members can also form an open frame, or haveadditional members as shown attached thereto. Typically, frame elementsthat are foldably connected through hinges are made at least in part ofmetal, wherein the hinges are attached to metal parts, for example, ametal member, of the frame elements. Frame elements can include one ormore members made of metal, typically, at least the member to which ahinge is attached is made of metal. Suitable metals include but are notlimited to aluminum and steel. Preferably, the metal members are madefrom hot-formed steel. Suitable hot-formed steel includes hollowstructural steel sections, I-beams and steel channels (typically,C-shaped cross-section). Typically, the hot-formed, steel is a hollowstructural steel section or a steel channel. Steel members can beconnected, for example, by welding to form a steel frame element.

Frame elements can include parts or have elements attached to them thatenable automatic guidance of the relative movement of foldably connectedframe elements during folding and/or unfolding.

Frame elements can further include parts or have elements attached tothem that enable automatic locking or bolting of foldably connectedframe elements in selected folding configurations.

Interior and exterior finish materials can be attached to the structuralframe, and, specifically, frame elements of the structural frame.Interior finish materials include but are not limited to wall finishing(for example, gypsum board and Advantech® sheathing), ceiling finishingand floor finishing (for example, Advantech® sheathing with Bambooflooring on top. Exterior finishing elements include but are not limitedto siding and roofing.

For finish materials, and, in particular, interior finish materials, ithas been found that “indirect connection” to the frame elements toreduce contact, partially or entirely, of the interior finish materialswith the frame elements is advantageous for one or more of the followingreasons. Reduced contact can (a) reduce the transfer of structuralstresses from one or more frame elements of the structural frame to theoften fragile and brittle interior finish materials thereby reducing oreliminating significant damage (such as dry wall cracking) of theinterior finish materials, in particular, during folding, uploading,transporting, unloading and/or unfolding of the foldable building unit,(b) reduce or eliminate the exposure of the interior finish materials towater, for example, water that can condensate on metal parts of theframe elements, and (c) reduce heat transfer between the inside of thefinished building unit to the outside of the finished building unit.

Thus, generally, it is preferred to use indirect rather than directconnections of finish materials, particularly, interior finish materialswith respective frame elements. However, even though indirectconnections are typically preferred, not all connections betweeninterior finish material and a respective frame element have to beindirect.

Indirect connections are particularly preferable for frame elements madeentirely from metal, that is, metal frame elements. However, even though“indirect connections” are favorable, direct connections (e.g., glue,screws, nails etc.) can also be present, even to metal parts of theframe elements.

Indirect connections can be provided through intermediate elements.Intermediate elements can be made of a plurality of materials.Preferably, intermediate elements are made, at least in part, ofmaterials that have a force cushioning effect, that is, force cushioningelements such as, for example, wood, sprayed foam, and light-gaugealuminum studs. Typically, an intermediate element is positioned anddimensioned such that it can connect or can be connected (e.g., usingpowder-actuated fasteners or self-tapping screws) to the frame elementthrough one area of the intermediate element (e.g., through one side ofthe intermediate element) and that it can be connected to the finishmaterial, particularly, the interior finish material (for example, usingnails or screws) through another area of the intermediate element (e.g.,through another side of the intermediate element). Even more preferably,intermediate elements are entirely made of force cushioning materialssuch as wood. Foldable building units of the present invention caninclude wall panels, roof and floor sections that are in substantiallyfinished condition, that is, with the exception of unfinished areasdimensioned to accommodate folding of the frame elements, and unfinishedareas due to wall connection seams (i.e., seams between walls that arenot connected but upon unfolding jointly form a wall), these wallpanels, roof and floor sections are finished.

“Finished panels” as referred to herein, are panels that include frameelements and interior finish materials connected (typically, indirectly)to them, and can also include elements such as doors and windows.Finished panels can be, for example, finished wall panels, finishedfloor panels, finished ceiling panels and finished roof panels.

“Metal hinges” as referred to herein, refers to hinges in which at leastthe load bearing parts (including hinge leaves, hinge knuckles and hingepin(s)) are made of metal. Preferably, the entire hinge is made ofmetal. Preferably, the metal is steel.

“Offset hinges” as referred to herein, are hinges that include at leasttwo hinge leaves that are foldably connected and provide an offsetbetween the two hinge leaves in folded configuration. Offset hinges caninclude two hinge leaves that are foldably connected around one, two,three or more axes. An offset set hinge that provides for one axis ofrotation is hereinafter also referred to as a “fixed-axis hinge.”Preferably, fixed-axis hinge is made of two hinge leaves that haveextended hinge knuckles attached thereto, wherein the extended hingeknuckles extend around a hinge pin to foldably connect the hinge leaves.For an offset hinge, the extension provided by each of the extendedhinge knuckles can be of the same length or they can be different.Typically, the extension provided by each of the extended hinge knucklesof an offset hinge is the same. Extended hinge knuckles of differentextension lengths can be desired if, for example, the thicknesses of twoframe element that are to be foldably connected is different. The largerthe extensions provided by the extended hinge knuckles of an offsethinge are, the larger can be the offset between interior finishmaterials connected (typically, indirectly) to the frame elements.

Typically, at least the load bearing parts (including hinge leaves,extended hinge knuckles, and hinge pin(s)) of offset hinges are made ofmetal. Preferably, the entire offset hinge is made of metal. Preferably,the metal is steel.

An offset hinge that provides for two, three or more axes of rotation ishereinafter also referred to as a “step-out hinge.” With increasingnumber of axes that are being provided by the step-out hinge, thedegrees of freedom for folding increase, however, at the same timecontrolling the folding process becomes increasingly difficult.Preferably, step-out hinges provide for three axis of rotation (i.e.,three-axis step-out hinge). More preferably, a step-out hinge includes afirst hinge leaf, a second hinge leaf, a first center hinge leaf and asecond hinge leaf, wherein the first hinge leaf is foldably connected tothe first center hinge leaf, the first center hinge leaf is foldablyconnected to the second center hinge leaf, and the second center hingeleaf is foldably connected to the second hinge leaf. It has been foundthat step-out hinges with a plurality of axes provide advantageousfolding flexibility relative to single axis hinges. Typically, at leastthe load bearing parts (including hinge leaves, extended hinge knuckles,and hinge pin(s)) of step-out hinges are made of metal. Preferably, theentire step-out hinge is made of metal. Suitable metals include steel.Hinges can be attached via their respective hinge leaves to frameelements to foldably connect the frame elements. In the preferred caseof metal hinges that are to be attached to metal parts of frameelements, for example, metal members or entire metal frame elements, thehinges can be attached, for example, by welding. Typically, hinge leavesof metal hinges are welded to frame elements using methods known in theart.

Hinges and, in particular, offset hinges and step-out hinges (which canalso be offset hinges) allow for a plurality of folding configurationsassociated with respective relative positions of the hinge leaves andrespective attached frame elements. Typically, the step-out hingessuitable in the present invention provide an offset. For example, FIG. 9provides a perspective view of four folding configurations of athree-axis step-out hinge providing an offset in the foldedconfiguration. Typically, for a three-axis step-out hinge the foldedconfiguration is as shown at the bottom of FIG. 9. If interior finishmaterials are connected (typically, indirectly) to the frame elementssuch that they face each other in the folded configuration, thethree-axis step-out hinge provides an offset in the foldedconfiguration, that is, it offsets the interior finish materials fromeach other. If the hinge is used to foldably connect two frame elementsthat jointly form a flat surface, for example, a floor in the finishedbuilding unit, the folding configuration as shown at the top cancorrespond to the unfolded configuration. If the hinge is used tofoldably connect two frame elements that jointly form, for example, a 90degrees wall corner in the finished building unit, the third foldingconfiguration from the top shown in FIG. 9 can correspond to theunfolded configuration. If the two foldably connected frame elements aredesired to be placed at different angles in the finished building unit,other folding configurations of the three-axis step-out hinge cancorrespond to the unfolded configuration.

Hinges and/or frame elements can further include spacer elements (see,e.g., Feature 1110 in FIG. 11) that are sandwiched between the hingeleaves and frame elements such that a desired unfolded configuration ofthe foldably connected frame elements is achieved. In addition oralternatively, hinge leaves, parts of a member of a frame elements,members of a frame element or entire frame elements can have differentdimensioned to achieve a jointly formed planar surface.

The hinges used in the foldable building units of the present inventioncan be adapted and positioned to remain within the building unit inunfolded configuration and finished condition.

A spacer element can be part of the three-axis step-out hinge, inparticular, one of the hinge leaves of the three-axis step-out hinge canhave a thickness that obviates the spacer element. The spacer elementcan also be part of the frame element, for example, the frame elementmay have a thickness in the area to which the hinge leave is to beattached that obviates the need for a spacer element. Alternatively, thespacer element can be a separate element that can be attached to thehinge leave and frame element. Typically, a spacer element is made ofmetal, preferably, of steel.

For foldable building units that are pre-fabricated to include interiorfinish material, it is desirable that the foldable building unit infolded configuration can be uploaded, transported and unloaded withoutsignificant direct contact of finish materials of the folded panels. Ithas been found that contact can be reduced or entirely prevented byusing appropriately dimensioned offset hinges to foldably connect frameelements that have interior finish materials attached to them.

The foldable building units of the present invention can be unfolded ona building site to provide part of or an entire building. Generally,after unfolding of the foldable building unit some finishing work at thebuilding site is required.

A foldable building unit in “finished condition” refers to a buildingunit that is ready for commercial or private use.

An advantage of the foldable building units of the present invention isthat they can be prefabricated to the extent that these building unitsare substantially in finished condition after unfolding, requiringsignificantly less labor after unfolding on the building site than onespreviously described.

The foldable building units of the present invention are foldable tofacilitate transport of the pre-fabricated building units. Preferably,the foldable building units in folded configuration are dimensioned suchthat transport with a transport vehicle, preferably, a semitrailer doesnot require a special transport permit. Regulations pertaining to theoperation of trucks and trailers vary from country to country, and, insome instances from state to state. For example, currently, in at leastone state of the United States of America, the length of a semitrailerincluding a foldable building unit can be up to 53 feet withoutrequiring a commercial drivers license, the width of a semitrailerincluding a foldable building unit can be up to 102 inches withoutrequiring a commercial drivers license, and the height of a semitrailerincluding a foldable building unit can be up to 13 feet, 6 incheswithout requiring a commercial drivers license.

A “transport vehicle” as referred to herein, is a vehicle that is suitedfor transporting a foldable building unit along roads to a buildingsite. Typically, the transport vehicle is a semitrailer.

A “ground-level lifting rig” as referred to herein, is a device that isadapted to move a load, typically, lift a load and contains at least onelifting member that can be connected to a foldable building unit. Aground-level lifting rig is designed with regard to its structuralstability and lift power such that it can be used in lifting of afoldable housing module without structural damage to the lifting rig.Ground-level lifting rigs are typically portable. Also, they arepreferably small for ease of transport along with the foldable buildingunit, for example, on the transport vehicle that transports the foldablebuilding unit. Ground-level lifting rigs can be manually powered (e.g.,a manual hoist) or use another source of energy (e.g., electrical energyused with an electric hoist, electric hydraulic system, air power lift,etc.). Ground-level lifting rigs can be adapted such that they can beplaced on various types of surfaces that can be even, uneven, and/orwith or without slope.

A “lifting member” as referred to herein, is a part of a ground-levellifting rig that can be connected to connection members or directly to afoldable building unit and is moved during lifting of the foldablehousing module. A lifting rig can have one or more lifting members.Typically, it has one lifting member. The lifting member can be any partthat can be temporarily contacted or attached to a connection member ordirectly with a foldable building unit and is adapted to maintaincontact or attachment during lifting and/or lowering of the foldablebuilding unit.

A “connection member” as referred to herein, is a part that is eitherpart of the structural frame or can be attached to the structural frame,and can be connected to the lifting member of a ground-level lifting rigand is adapted to maintain connection between the foldable building unitand the lifting member of the ground-level lifting rig during liftingand/or lowering of a the foldable building unit.

Polymer gaskets can be used to cover seams or folds of foldablyconnected members (e.g., hollow structural steel sections) of respectiveframe elements as well as hinges (including offset and step-out hinges).Suitable polymer gaskets are sufficiently flexible to prevent tearing ofthe polymer gasket during folding and unfolding, do not hinder foldingand unfolding and are preferably not permeable for water. An example isshown in FIG. 13.

Seams or folds of foldably connected frame elements, and preferably allboundaries of folded components, can be sealed with polymer gaskets atthe time of prefabrication to reduce or remove the need fortime-consuming and error-prone on-site weatherproofing.

While this invention has been particularly shown and described withreferences to example embodiments thereof, it will be understood bythose skilled in the art that various changes in form and details may bemade therein without departing from the scope of the inventionencompassed by the appended claims.

1. A foldable building unit comprising (a) a structural frame that atleast in part is made of frame elements that are foldably connected withmetal hinges; and (b) interior finish materials with indirect connectionto the frame elements to reduce contact of the interior finish materialswith the frame elements; wherein the frame elements are at least in partmade of metal and the metal hinges are attached to a metal part of theframe elements.
 2. The foldable building unit of claim 1, wherein theframe elements and respective interior finish materials are indirectlyattached through intermediate elements adapted and configured to preventsignificant damage of the interior finish materials during folding,uploading, transport, unloading and/or unfolding of the foldablebuilding unit.
 3. The foldable building unit of claim 2, wherein theintermediate elements are force cushioning elements.
 4. The foldablebuilding unit of claim 3, wherein the force cushioning elements includebottom plate elements and top plate elements that are fastened to theframe elements and to which the interior finish materials are attached,and the foldable building unit further comprises stud elements betweenbottom plate elements and top plate elements. 5-6. (canceled)
 7. Thefoldable building unit of claim 1, wherein the metal hinges are adaptedand positioned to remain within the foldable building unit in finishedcondition. 8-9. (canceled)
 10. The foldable building unit of claim 1,wherein the frame elements are made of structural steel sections. 11.The foldable building unit of claim 1, wherein the foldable buildingunit is a foldable building.
 12. The foldable building unit of claim 11,wherein the foldable building in unfolded configuration is substantiallyin finished condition.
 13. (canceled)
 14. A foldable building unitcomprising a structural frame that at least in part is made of frameelements that are foldably connected with offset hinges, wherein theoffset hinges are attached to metal parts of the frame elements and theoffset hinges are adapted and positioned on the frame elements such thatwhen folded, interior finish materials connected to the frame elementsare offset from each other. 15-16. (canceled)
 17. The foldable buildingunit of claim 14, wherein the offset is dimensioned to preventsignificant contact of interior finish materials in folded configurationduring uploading, transport and/or unloading of the foldable buildingunit.
 18. The foldable building unit of claim 14, wherein the offsethinges are adapted and positioned to remain within the building unit inunfolded configuration and finished condition.
 19. The foldable buildingunit of any one of claims 14, wherein the frame elements are made ofstructural steel sections. 20-21. (canceled)
 22. The foldable buildingunit of claim 14, wherein the foldable building unit is a foldablebuilding.
 23. The foldable building unit of claim 22, wherein thefoldable building in unfolded configuration is substantially in finishedcondition.
 24. (canceled)
 25. A foldable building unit comprising astructural frame that at least in part is made of frame elements thatare foldably connected with metal hinges, wherein the frame elements areat least in part made of metal, the metal hinges are attached to a metalpart of the frame elements, and the metal hinges are adapted andpositioned to remain within the building unit in unfolded configurationand finished condition.
 26. The foldable building unit of claim 25,wherein the frame elements are made of structural steel sections. 27-28.(canceled)
 29. The foldable building unit of claim 25, wherein thefoldable building unit is a foldable building.
 30. The foldable buildingunit of claim 29 wherein the foldable building in unfolded configurationis substantially in finished condition.
 31. (canceled)
 32. A foldablebuilding comprising (a) foldably connected finished wall panels; (b)foldably connected finished floor panels; and (c) foldably connectedfinished ceiling and/or roof panels; wherein the foldable building inunfolded configuration is substantially in finished condition. 33-55.(canceled)
 56. A foldable building comprising a foldable clerestory roofincluding a clerestory truss frame element foldably connected to a firstroof frame element on a first side of the clerestory truss frame elementand foldably connected to a second roof frame element on a second sideof the clerestory truss element, wherein the second side is opposite tothe first side.
 57. The foldable building of claim 56, wherein thefoldable clerestory roof in folded configuration provides an outersurface of the foldable building in folded configuration.